Mortar packages for masonry construction

ABSTRACT

Pre-filled mortar packages are positioned between masonry construction elements (such as stones, blocks or bricks) when forming a wall (such as a dry-stack stone wall). Each mortar package includes an outer covering with a porous outer surface, a mortar mixture covered by the outer covering, and (optionally) an adhesive incorporated onto or in the porous outer surface. Both the adhesive and the mortar mixture are activated by a liquid, such as water. The mortar packages may be pre-wetted before placement or may be dry when placed and then activated by applying water or by wetting from rain water. Toroidal shaped mortar packages are used as footers for posts and poles. Tubular shaped mortar packages are used as drainage ports through masonry construction or to protect buried lines.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/158,019, filed Jan. 17, 2014, now pending.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of the present invention is mortar packages and methods ofusing mortar packages, particularly for masonry construction.

2. Background

Masonry elements, such as stone walls, serve many practical purposes andcan add value to a property. For example, when stones or bricks are usedto form a retaining wall, a property owner can change the landscape of asloping yard into one that is more functional. Walls can serve asdemarcation lines that define the boundaries of a property. In addition,walls may improve aesthetics or visual interest of a property.

Dry stacking is one method of building a stone wall. A dry-stackedretaining wall is built by vertically stacking stones of various width,length, and thickness. As the stones are stacked, crevices between thestones are filled with sand, gravel, and smaller stones. Gravity andfriction hold the stones together, usually without any type of mortar oradhesive or additional reinforcement. Stacking stones is laborintensive. As a wall is built, smaller rocks typically are broken offfrom larger stones and shaped to fit in gaps in the wall for levelingpurposes.

Over time, however, the stones used to build dry-stacked walls shiftfrom their initial positions. This shifting is worsened by weathereffects (e.g., rain, snow, wind) and other stressors that loosen thesand, gravel, and small stones positioned in crevices in the dry stackedwall. Although some open crevices are acceptable for water drainagepurposes, these crevices will eventually enlarge and adversely affectthe structural integrity of the wall.

To deter the shifting and movement of stones many professionalcontractors reinforce the interior of walls with mortar. Using mortaronly on surfaces of stones that are placed within interior portions ofthe wall can preserve the exterior look of a dry-stacked stone wall.Unfortunately, applying mortar to the interior of the wall is at least atwo-person or more person job. In the case of two persons or more, oneperson continuously mixes and prepares mortar slurry for application,while at least one other person stacks stones to form the wall andapplies the mortar as it is needed.

Conventional methods of dry stacking and reinforcing masonry walls canbe improved upon. Dry-stacked stone walls will at some point requirereinforcement because of the shifting and movement of stones. But themethods of addressing these problems require at least two people and arelabor intensive. For these reasons, among others, there is a clear needfor improved masonry construction methods. The present inventionfulfills this need and provides further related advantages, as describedin the following summary.

Conventional methods for installing support posts or poles in the groundgenerally require that a post hole be dug, and that a bottom portion ofthe post hole be filled with concrete or a mixture of stone and concreteto create a footer to support the post or pole. After the post or poleis inserted into the hole, additional concrete is poured into the holeto secure the bottom portion of the post or hole. Then, the remainingopen space around the post or pole is filled with dirt. The pouredfooter can have an uneven surface and there is not an exact measure forthe amount of concrete poured around the post or pole within the hole.Improvements to installing support posts or poles continue to be sought.

Electric lines and water lines often are buried in the ground with noencasement or plastic encasement. Improvements to protect these buriedlines from puncture continue to be sought.

SUMMARY OF THE INVENTION

The present invention is directed towards mortar packages and methods ofusing mortar packages for masonry construction. Instead ofconventionally stacking stones to form dry-stacked stone walls andreinforcing these walls with sand, gravel, small stones, and/orconcrete, mortar packages are positioned between masonry constructionelements. Mortar packages may be shaped or compressed when installed tobetter level and stabilize wall surfaces.

A mortar package includes an outer covering, having a porous outersurface. Incorporated into or on the porous outer surface is anadhesive. A mortar mixture, which is preferably dry, is held within andcovered by the outer covering. Both the adhesive and the mortar mixturepreferably are activated by a liquid (e.g. water), where the term“activated” is defined herein as the setting of product constituents forbonding purposes.

In one variant, the mortar package has an outer covering forming atoroid about a central axis and defining a void at said central axis.The outer covering has a porous outer surface and defines an internalvolume disposed around said central axis. A mortar mixture is heldwithin the internal volume of the outer covering, and optionally anadhesive is incorporated in or on at least a portion of the porous outersurface. The toroid shape may be donut-shaped, square-shaped,rectangular-shaped, oval-shaped, round-shaped, circular-shaped, andtube-shaped. The voids or void spaces of the toroidal mortar packagesare adapted to receive structures, such as posts or poles or water linesor power lines. The toroidal mortar packages may be used when installingfooters for building construction, or may be used to form drainage portsor passageways in masonry construction.

A more complete understanding of various configurations of the mortarpackages and single-person methods of using mortar packages will beafforded to those skilled in the art, as well as a realization ofadditional advantages and objects thereof, by consideration of thefollowing detailed description. Reference will be made to the appendedsheets which will first be described briefly.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only and notintended to limit the scope of the present disclosure. Like elementnumerals may be used to indicate like elements appearing in one or moreof the figures.

FIG. 1 shows one configuration of mortar package;

FIG. 2 shows a cross-sectional view of the mortar package shown in FIG.1 taken along line 2-2 of FIG. 1;

FIG. 3 shows a one type of stacked stone wall, including mortar packagesdisclosed herein;

FIG. 4 shows a cross-sectional view of the stone wall shown in FIG. 3taken along line 4-4 of FIG. 3;

FIG. 5 shows another type of stacked stone wall, including the mortarpackages disclosed herein;

FIG. 6 shows a cross-sectional view of the stone wall shown in FIG. 5taken along line 6-6 of FIG. 5;

FIG. 6A shows a cross-sectional view of the stone wall shown in FIG. 5taken along line 6A-6A of FIG. 5;

FIG. 7 shows a person holding an exemplary mortar package, and a bucketcontainer filled with an activation liquid and having mortar packages ofvarious sizes and shapes soaking in such activation liquid;

FIG. 8 outlines steps in a single-person method of using mortar packagesfor masonry construction;

FIG. 9 shows a perspective view of an alternative configuration ofmortar package;

FIG. 10 shows a perspective view of another alternative configuration ofmortar package;

FIG. 11 shows a perspective view of a post installation with a mortarpackage of FIG. 9 used as a footer;

FIG. 12 shows a perspective view of a post installation with a pluralityof mortar packages of FIG. 9 used as footers;

FIG. 13 shows a perspective view of a pole installation with a mortarpackage of FIG. 10 used as a footer; and

FIG. 14 shows a perspective view of still another configuration ofmortar package.

DETAILED DESCRIPTION

Turning in detail to the drawings, FIG. 1 shows one configuration of amortar package 10, which is generally pillow-shaped. These types ofmortar packages are particularly useful for masonry construction. Theterm “masonry,” however, should be broadly construed to relate to thebuilding of structures from individual units, such as stones, blocks,and bricks, which are laid in one or more substantially linearformations. A mortar package includes an outer covering 12, having aporous outer surface 14 and an adhesive 16 incorporated into at least aportion of the porous outer surface. The outer covering 12 covers amortar mixture 20, as shown in FIG. 2.

The outer covering 12 may have various configurations. For example, asshown in FIG. 2, the outer covering 12 can include an upper sheet 22 anda lower sheet 24. Both sheets have edges 26, 28 that may be joinedtogether in various manners, such as bonded or seamed with an edgesealant 29 or attachment element 30 around a covering perimeter 32. Thecovering perimeter 32 extends along at least three sides 34, 36, 38 ofthe mortar package 10. Alternatively, the outer covering may be acontinuous sheet of material, such that the covering forms a pouch orenvelope, having an opening, which may be joined or sealed after amortar mixture is inserted into or dispensed within the covering.

Each type of outer covering configuration includes a porous outersurface 14, optionally having an adhesive 16 incorporated therein orapplied thereon. The outer covering may, for example, be manufacturedfrom one or more woven fiber-based fabrics. Preferably, the material isbiodegradable, such that it disintegrates over time without negativeenvironmental consequences.

Burlap is one type of fiber-based fabric material that may be used forthe outer covering. It is eco-friendly, porous and biodegradable. Theadhesive 16 may be incorporated in or on the outer surface. The porousouter surface 14 has sufficient porosity such that a wetting oractivation liquid, such as water, may penetrate through the outersurface and into the interior of the mortar package.

The adhesive 16, which optionally is incorporated into the outer surface14, is liquid-activated (preferably water-activated) and capable ofbonding to stone, block and brick materials. The adhesive provides anadditional way to reinforce a masonry structure, beyond the use ofadhesives and mortar mixtures used alone. Adhesive types include, butare not limited to adhesives that are resin-based and water-based orwater-soluble. Representative adhesives include moisture curingadhesives such as cyanoacrylates, urethanes, rubber cements, glues orpolyvinyl acetate dispersions, and pressure sensitive adhesives such asacrylate based polymers. Bioadhesives also may be used. One suitableadhesive is High Tack Fish Glue (CAS# 9000-70-8) from Norland Products,Inc. of Cranbury, N.J.

A mortar mixture 20 is held or disposed within the inner volume definedby the outer covering 12, and is covered by the outer covering 12, asparticularly shown in FIGS. 2, 4, and 6. The mortar mixture 20 may beany type of mixture suitably used for building and bonding masonrystructures. Such mortar mixtures traditionally include cement (e.g.,Portland cement), lime, and an aggregate, such as sand. The mixtures arepreferably dry, pre-mixed, powdered mixtures, which are activated byliquid, usually water. The mortar mixture 20 has a density and powderparticle size range that allows the package 10 to be pliable, such thatit can fit between masonry construction elements 40 of various sizes andshapes. Mortar mixes can be characterized by strength as follows: Type Nis a medium strength mortar most often used for non-loadbearing brickwalls and soft stone masonry; Type S is a higher strength mortar knownfor its ability to absorb most impacts, and can be used for patios,foundations and retaining walls; and Type M is a high strength mortarmost often used with retaining walls and stone structures because it canbear heavier loads. Any of these mortar mixes is appropriately used withthe present invention.

FIGS. 3 and 4 show one type of stone wall 50, which includes masonryconstruction elements 40 of various sizes and shapes, and mortarpackages 10 a, 10 b installed at locations between some of the masonryconstruction elements 40. This type of wall includes a plurality ofstones 52 with some stones having at least one substantially flatsurface 54. These types of stones are typically used for dry-stackingwalls.

The cross-sectional view of the wall shown in FIG. 4 includes a capstone 56 positioned on the top of the wall, a set stone 58 positioned onthe bottom of the wall, and intermediate stones 60 positioned betweenthe cap stone 56 and the set stone 58. Mortar packages 10 a, 10 b arepositioned in crevices or openings 66 between adjacent stones in thewall to provide reinforcement at an interior section 64 of the wall. Themortar packages 10 a, 10 b are used to reinforce and level the wall 50.

FIGS. 5 and 6 and 6A show another type of stone wall 70, which includesmasonry construction elements 40 of various sizes and shapes and mortarpackages 10 c, 10 d. This type of wall includes a plurality of stones 72with stones having irregularly shaped surfaces 74. These types of stonesare typically not used for dry-stacking. Due to the compliant nature ofthe mortar packages 10 c, 10 d, a wall which is structurally sound maybe built by stacking the stones and positioning the mortar packagesbetween some of the stones.

The cross-sectional view of the wall shown in FIG. 6 includes a capstone 76 positioned on the top of the wall, set stones 78 positioned onthe bottom of the wall, and intermediate stones 80 positioned betweenthe cap stone 76 and set stones 78. Mortar packages 10 c, 10 d arepositioned in crevices or openings 75 between adjacent stones in thewall 70 to provide reinforcement at an interior section 75 of the wall.The mortar packages 10 c, 10 d are used to reinforce and providestructural integrity to the wall 70. FIG. 6A shows anothercross-sectional view of the wall of FIG. 5.

FIG. 7 shows mortar packages 11 a, 11 b, 11 c, 11 d, 11 e of variousshapes and sizes. The alternative shaped and sized mortar packages allowa user 90 to hand select different types of mortar packages to positionin wall crevices or openings while constructing the wall. Shapes ofmortar packages include, but are not limited to tubular-shaped mortarpackages, triangular-shaped mortar packages 11 a, oblong orrectangular-shaped mortar packages 11 b, donut-shaped mortar packages 11c, rectangular or square-shaped mortar packages 11 d, and oval, round orcircular-shaped mortar packages 11 e. Mortar packages may have variedlength (or diameter), width and thickness as desired. One example of amortar package is a square-shaped mortar package 11 d, having a lengthand width of about 2 to 8 inches, and a thickness of about 1 to 4inches, preferably about 1 to 2 inches. The mortar packages of theinvention may have dimensions anywhere from 2 inch by 2 inch square, to2 foot by 2 foot square, or up to 2 foot in diameter for round or ovalshapes.

FIG. 7 also shows how both the optional adhesive 16 and the mortarmixture 20 can be activated by pre-soaking. A user 90 may activate theadhesive 16 and mortar mixture 20 by soaking mortar packages 10 in abucket or container 92 with an activation liquid 94, such as water 96therein. Alternatively, the activation liquid 94 may be applied to themortar package by wetting mortar packages after they are positioned in awall. Wetting may occur by hosing down the wall or dousing interiorsections of the wall that include the mortar packages with water. Asstill another alternative, a user may allow a soaking rainfall to wetthe wall and thereby indirectly wet the mortar packages to activate theadhesive and mortar mixture.

Together, the optional adhesive 16 and the mortar mixture 20 of themortar packages bond masonry construction elements 40 to one another.There is advantage to the combination of adhesive 16 and mortar mixture20 where an adhesive may be selected to more rapidly set and secure themortar package to the masonry elements, giving time for the mortarmixture to cure. As such, mortar packages 10, 11 may be used to formwalls with increased strength, compared to those which use adhesives ormortar alone. These walls are also less susceptible to weather damageand more resistant to other damage.

The mortar packages 10, 11 when installed may act as a balancer oranti-rock dampener to keep the masonry construction elements 40,particularly those with irregular surfaces such as stones, from rockingor working loose from the wall or other masonry structure.

FIG. 8 shows a series of steps for a single-person method 100 of usingthe mortar packages, described herein, for masonry construction. Thesesteps include:

-   -   Positioning at least one mortar package, having an outer        covering with a porous outer surface, an adhesive incorporated        into the porous outer surface and a mortar mixture covered by        the covering, between two or more masonry construction elements        102;    -   Activating the adhesive incorporated in or on the porous outer        surface 104; and    -   Activating the mortar mixture covered by the outer covering 106.

FIG. 9 shows an alternative configuration of a mortar package 200 thatforms a toroid with a square-shaped void space 210 surrounded by themortar filled covering. The outer covering 212 has a porous surface andmay be coated with adhesive, as described above for mortar packages ofpillow configuration. A mortar mixture 220 is held within internalvolume space bounded by the outer covering 212. The covering perimeter232 may be bonded with edge sealant or other attachment element, such asbut not limited to sewing, to hold the mortar mixture 220 in the mortarpackage 200.

Referring now to FIG. 11, one mortar package 200 may be installed withina hole 302 to form a support or footer for a post 300. The mortarpackage 200 may be pre-wet or soaked in water before inserting themortar package 200 into the hole 302. Then, the post 300 may be insertedinto the hole 302 and into the void 210 in the mortar package 200. Asyet another alternative, the mortar package 200 may be inserted into thehole 302, and the post 300 may be inserted into the hole and the void210 before the mortar package 200 has been wetted to activate theadhesive and mortar. In this alternative method, once the mortar package200 and post 300 are installed in the hole 302, water may be poured intothe hole around the post 300 to activate the adhesive and the mortar.After the mortar is set (e.g., dried), the hole may then be refilledwith dirt. The resulting support structure resists frost heave and ismore uniformly supporting the post 300 in the hole 302.

FIG. 12 shows another option for mounting a post 300 into the ground.Here, multiple mortar packages 200A, 200B and 200C are set into the hole302 in stacked relation with their void spaces 210 aligned. The post 300then may be inserted into the hole 302 and into the voids 210 in themortar packages 200A, 200B and 200C. In one method, the mortar packages200A, 200B and 200C are pre-wet or soaked in water before they areinstalled into the hole 302. In an alternative method, the mortarpackages 200A, 200B and 200C are installed into the hole 302, and thepost 300 is inserted into the hole and into the voids 210 in the mortarpackages 200A, 200B and 200C first. Then, water is poured into the hole302 around the post 300 to active the adhesive and the mortar. Theembodiment shown in FIG. 12 has advantage of enhanced stability andresistance to frost heave.

In one variation of this method, once the hole 302 is dug, first, atleast one mortar package 10 is placed in the hole. This form of mortarpackage 10 is not a toroid and lacks a void space. Then, one or moremortar packages 200 may be installed or set in stacked relation over thefirst mortar package 10. Then, the post 300 is inserted into the hole302 and into the voids or void spaces 210 in the mortar package(s) 200.

Referring now to FIG. 10, a mortar package 280 may be formed in adonut-shape or a toroid with a round annular shape surrounding a voidspace 288. The mortar package 280 also has a porous outer covering 284that optionally may be coated with adhesive. A mortar mixture is heldwithin the volume space defined by the covering 284. The outer coveringperimeter 282 may be bonded with edge sealant or other attachmentelement, such as but not limited to sewing, to hold the mortar mixturein the mortar package 280.

FIG. 13 shows one mortar package 280 may be installed within a hole 302to form a support or footer for a pole 310. The mortar package 280 maybe pre-wet or soaked in water before inserting the mortar package 280into the hole 302. Then, the pole 310 may be inserted into the hole 302and into the void 288 in the mortar package 280. As yet anotheralternative, the mortar package 280 may be inserted into the hole 302,and the pole 310 may be inserted into the hole and the void 288 beforethe mortar package 280 has been wetted to activate the adhesive andmortar. In this alternative method, once the mortar package 280 and pole310 are installed in the hole 302, water may be poured into the holearound the pole 310 to activate the adhesive and the mortar. After themortar is set (e.g., dried), the hole may then be refilled with dirt.The resulting support structure resists frost heave and is moreuniformly supporting the pole 310 in the hole 302. As yet anotheralternative, comparable to the structure shown in

FIG. 12, multiple mortar packages 280 could be inserted into a hole 302in stacked relation with their void spaces aligned. One end of the pole310 may be inserted into the hole 302 and into the void spaces of thestacked mortar packages 280. The stacked mortar packages could bepre-wet or soaked before their insertion into the hole 302, or could bewet after the pole 310 is installed therein.

Optionally, a footer may be formed by inserting one or more mortarpackages 200, 280 into a hole 302 and activating the adhesive and mortarby wetting. Because the mortar packages 200, 280 have void spaces 210,288, a post or pole may be inserted into the void space(s) after theadhesive and mortar have set (dried). Multiple mortar packages 200A,200B, 200C could be stacked, activated and set to form a footer in onehole before installing a post or pole.

FIG. 14 shows yet another alternative mortar package 400 shaped as anelongated tube with a central channel 402. The mortar package 400preferably has a porous surface that may be coated with an adhesive. Amortar composition is held within the inner volume of the mortarpackage. A water line or an electrical line or multiple lines intendedfor installation in ground may be threaded through the elongated tubeand held in the central channel 402. The mortar package 400 then may beburied in the ground and forms a protective shield to the line(s) heldtherein. The mortar package 400 may be pre-wet or soaked prior toinstalling in the ground, or water may be poured onto the mortar packageafter it has been laid into a trench or hole in the ground. Once theadhesive and mortar are set, the mortar package 400 resists penetrationor puncturing, and thus better shields the water line or electric line.

The mortar package 400 of FIG. 14 may be used also to form a drainageport or passageway or hole through a wall. In such embodiment, themortar package 400 is installed between stones or between other masonryconstruction elements as a wall is formed. The adhesive and mortar maybe activated by pre-wetting or soaking the mortar package 400 prior toplacing it between masonry construction elements.

While embodiments of this invention have been shown and described, itwill be apparent to those skilled in the art that many moremodifications are possible without departing from the inventive conceptsherein. The invention, therefore, is not to be restricted except in thespirit of the following claims.

1. A mortar package, comprising: an outer covering forming a toroidabout a central axis and defining a void at said central axis, saidouter covering having a porous outer surface and defining an internalvolume disposed around said central axis; a mortar mixture held withinthe internal volume of the outer covering; and an adhesive incorporatedin or on at least a portion of the porous outer surface.
 2. The mortarpackage of claim 1, wherein the outer covering comprises at least onesheet of fibrous material.
 3. The mortar package of claim 1, wherein theouter covering comprises an upper sheet and a lower sheet.
 4. The mortarpackage of claim 3, wherein the upper sheet and the lower sheet arejoined together along a covering perimeter.
 5. The mortar package ofclaim 1, wherein the outer covering comprises a biodegradable material.6. The mortar package of claim 1, wherein the adhesive iswater-activated.
 7. The mortar package of claim 1, wherein the mortarmixture is concrete or concrete based.
 8. The mortar package of claim 1,wherein the toroid is a shape selected from the group consisting of:donut-shaped, square-shaped, rectangular-shaped, oval-shaped,round-shaped, circular-shaped, and tube-shaped.
 9. A method forinstalling a post or pole in ground, comprising: forming a hole; placingat least one mortar package in said hole, said mortar package comprisingan outer covering forming a toroid about a central axis and defining avoid at said central axis, said outer covering having a porous outersurface and defining an internal volume disposed around said centralaxis, a mortar mixture held within the internal volume of the outercovering, and an adhesive incorporated in or on at least a portion ofthe porous outer surface; and inserting one end of the post or pole intothe void of the at least one mortar package.
 10. The method of claim 9,further comprising pre-wetting the at least one mortar package beforeplacing the at least one mortar package in said hole.
 11. The method ofclaim 9, further comprising placing multiple mortar packages in stackedrelation one on top of the other in said hole.
 12. The method of claim9, further comprising pouring water into said hole to wet the at leastone mortar package.
 13. The method of claim 9, wherein the toroid is ashape selected from the group consisting of: donut-shaped,square-shaped, rectangular-shaped, oval-shaped, round-shaped,circular-shaped, and tube-shaped.
 14. The method of claim 9, furthercomprising first placing at least one first mortar package in said hole,wherein said at least one first mortar package has a face surfacewithout a defined void forming a toroid, wherein said at least onemortar package that does define a void then is placed over the at leastone first mortar package.
 15. A method for installing a water orelectric line in ground, comprising: forming a trench or hole; threadingthe line through a mortar package, said mortar package comprising anouter covering forming a toroid about a central axis and defining a voidat said central axis, said outer covering having a porous outer surfaceand defining an internal volume disposed around said central axis, amortar mixture within the internal volume of the outer covering, and anadhesive incorporated in or on at least a portion of the porous outersurface; and inserting the mortar package with line threaded thereininto the trench or hole.
 16. The method of claim 15, further comprisingpouring water into said hole to wet the mortar package.
 17. The methodof claim 15, further comprising covering exposed surface(s) of themortar package with dirt.
 18. The method of claim 15, wherein the toroidis a shape selected from the group consisting of: donut-shaped,square-shaped, rectangular-shaped, oval-shaped, round-shaped,circular-shaped, and tube-shaped.